Universal fastener for decking

ABSTRACT

A fastener for attaching grooved decking planks to a support member has a body defining an attachment opening spacing apart opposing legs that may extend from a lateral shoulder. The body may include a planar portion The legs may have varying front or rear edge configurations. The front end may have downward extending teeth. A nose may extend from the front end while a tail may extend from the rear end of the body. Adjacent fasteners may be joined by their respective noses and tails to form a collated series of fasteners.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 14/434,268, filed Apr. 8, 2015, which claims priority to U.S. Provisional Application Nos. 61/711,243, filed Oct. 9, 2012, and 61/779,071, filed Mar. 13, 2013, the content of each of which is hereby incorporated by reference in its entirety.

BACKGROUND

The invention relates to deck plank fasteners or clips for securing a deck plank to a joist and for supporting deck planks relative to one another. More particularly, the invention relates to a hidden deck plank fastener for use with deck planks having undercut side grooves which vary widely in terms of dimensions and material properties.

Hidden deck plank fasteners for planks with undercut side groove exist, and are typically specific to a type of plank, groove dimension, nub dimension, material, amongst other variables. It would be useful to have a fastener that is compatible with planks having different styles, groove types and dimensions, and materials.

SUMMARY

An embodiment of the fastener has a body extending from a front end to a rear end. The body has a generally flat portion defining a plane extending between two opposing edges. An attachment opening extends from a top surface to a bottom surface of the body. A first bellow extends from one edge of the body and transitions to a downwardly projecting first leg. An opposite second below extends from the opposite edge to a downwardly projecting second leg. Each leg has at least one prong projecting from a front edge thereof.

Another embodiment includes a series of fasteners. A first fastener has a body extending from a front end to a rear end. The body has a generally flat portion defining a first plane that extends between two opposing edges. The rear end has a tail projected rearward therefrom. The body defines an attachment opening extending from a top surface to a bottom surface thereof. A first leg extends obliquely from one edge of the body while an opposite second leg extends obliquely from the other edge of the body and includes an alignment member. A second fastener has a body extending from a front end to a rear end. The body has a generally flat portion defining a first plane that extends between two opposing edges. The front end has a nose projecting frontward therefrom. The body defines an attachment opening extending from a top surface to a bottom surface thereof. A first leg extends obliquely from one edge of the body while an opposite second leg extends obliquely from the other edge of the body and includes an alignment member. The first fastener tail is attached to the second fastener nose such that the first and second fasteners are positioned with the first and second planes being coplanar.

DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of a universal fastener according to the disclosure;

FIG. 2 shows a perspective view of another embodiment of the disclosed universal fastener;

FIG. 3 is a perspective view of a series of universal fasteners of FIG. 1;

FIGS. 4-9 display the representative steps of a typical assembly of a decking structure using the disclosed universal fastener;

FIG. 10 is a perspective view of another embodiment of the universal fastener;

FIG. 11 is an elevation view of one side of the fastener of FIG. 13;

FIG. 12 is an elevation view the opposite side of the fastener from FIG. 11;

FIG. 13 is an elevation view of the rear side of the fastener of FIGS. 11 and 12;

FIG. 14 is an elevation view of a collated series of the embodiment of universal fastener of FIG. 10;

FIG. 15 shows a collated series of fasteners with pre-set elongated securing members engaged;

FIG. 16 is a bottom view of the collated series of fasteners shown in FIG. 14;

FIG. 17 is an enlarged view of the nose-to-tail attachment of adjacent fasteners in the collated series;

FIG. 18A shows a front elevation view of the fastener of FIG. 10;

FIG. 18B is a bottom elevation view of the fastener shown in FIG. 18A;

FIG. 19 is a perspective view of a collated strip of another embodiment of the disclosed fastener;

FIG. 20 is a side elevation view of the collated strip of FIG. 19;

FIG. 21 is a rear perspective view of the embodiment of the singular fastener of the collated strip of FIG. 19; and

FIG. 22 is a side elevation view of the fastener of FIG. 21.

DETAILED DESCRIPTION

With reference to the drawings wherein like numerals represent like parts throughout the Figures, a universal fastener for use with a variety of decking planks and a collated series of universal fasteners is disclosed.

FIG. 1 depicts a first embodiment of the disclosed universal hidden fastener 10. As shown, the fastener has a body 12 and two opposing downwardly extending legs 14, each having frontward extending side prongs 16. The body 12 defines a generally planar top surface 13 a and generally planar bottom surface 13 b, and an attachment opening 18 extending therethrough. As shown, the generally flat or planar portion of the body 12 transitions to lip 22 via a bend 20 toward the rear end.

This embodiment includes a tail 24 extending from the lip 22 at the rear end and a nose 25 extending from the opposite front end. The tail 24 and nose 25 will be discussed in further detail below with reference to FIGS. 3A and 3B. Embodiments of the fastener exist with only a nose or only a tail, also described further below.

Here, the attachment opening 18 is surrounded, at least partially, by a radial dome or dimple 26. In the embodiments depicted in the Figures, the opening 18 is a bore that extends substantially perpendicularly through the flat body portion of the fastener. As shown, the bore opening 18 is rearwardly offset from the central axis of the dimple 26, thereby providing an angled radial surface. In the depicted embodiment, the radial surface is angled downwardly from the front/nose end toward the rear/tail end). Alternative embodiments exist with a bore that is angled obliquely relative to the flat body portion or centered relative to the dimple. However, the depicted preferred embodiment has been shown to exhibit particularly favorable fastener attachment properties during deck assembly. The angled surface of the dimple assists in promoting an advantageous angle of drive of a securing member during installation.

The embodiment of the fastener 10 shown in FIG. 1 is substantially flat at the front end. As shown in FIG. 2, the fastener 100 may include teeth 30 extending downward as bends in the opposite front corners of the body. The remaining elements of the fastener 100 are substantially similar to the fastener 10 and thus not identified with separate reference numerals.

Typically, the smooth or flat front end of the fastener 10 is advantageous for use with natural decking planks (such as wooden) because it will not penetrate the wood surface, thereby reducing or preventing splitting of the plank material. The fastener 100 with teeth 30 is advantageous for use with composite decking planks. Penetration of the teeth 30 into composite or similar plank material significantly increases the strength and rigidity of attachment and restrains shifting effects from thermal expansion and contraction.

FIG. 3 depict a collated series 200 of universal fasteners. The fasteners that form the depicted series 200 are similar to the embodiment of FIG. 1 (no teeth projecting from the body). Clearly, fasteners with teeth may be attached at adjacent nose/tail interfaces to form a similar collated series as well. As shown, the lead fastener 201 may not include a nose extending from its front end, whereas the trailing fastener 203 may not include a tail, since neither is attached to an adjacent fastener at the respective position. Conversely, each of the intermediate fasteners, represented generally as reference numeral 205 in FIG. 3A, includes both a nose and a tail (essentially equivalent to the embodiment of fastener from FIG. 1). As shown, each fastener in the collated series is connected to the adjacent fastener(s) via attachment of the nose with an adjacent tail and/or vice versa. Thus it can be appreciated that a nose is unnecessary on the leading fastener 201, as a tail is unnecessary on the trailing fastener 203. It can also be appreciated that any of the fasteners may include both a nose and tail to accommodate preferred manufacturing and tooling techniques. FIG. 3A depicts a series with five fasteners total (three intermediate fasteners between a lead fastener 201 and a trailing fastener 203), but the depicted number of fasteners in a single collated series is non-limiting. FIG. 17 is an enlargement of a representative tail 24 of a fastener joined to an adjacent nose 25 of another fastener. As can be seen, the collation includes a notch 136 cut into the top and bottom portions of the metal forming the adjacent tail and nose which assists in separation of the adjacent clips during attachment of a fastener to a plank, typically by driving an elongated securing member through the attachment opening of the lead fastener (described in further below).

FIGS. 4-9 collectively depict the steps of a typical installation of a decking surface with the disclosed universal fastener.

FIG. 4 shows a section of a first grooved decking plank 40 on a support member 42, such as a joist (also in sectional view). As represented in FIG. 5, the front end of the fastener 100 with teeth 30 is inserted into the groove 44 and an elongate securing member (such as a screw or nail) 46 is driven through the attachment opening 18 (not seen in FIG. 5) and into the joist 42. The downward force of the securing member 46 drives the legs 14 to penetrate the joist surface. The downward penetration of the legs 14 is stopped by the lower surface of the fastener body 12 abutting or mating substantially flush with the lower nub of the decking plank, as shown best in FIG. 6.

FIG. 6 shows a universal fastener 100 installed in groove of a decking plank, attaching the plank 40 to the support member 42. The front end (here, with teeth 30 penetrating into the lower plank nub 41) traps the lower nub 41, thereby securing the plank to the support member. FIGS. 6 and 7 best show the rear lip 22 “open end” of the installed fastener 100 prior to receipt of a second or trailing decking plank. The enlarged image of FIG. 7 also clearly shows the press-fit between the fastener 100 and the securing member head.

As can be seen with reference to FIGS. 7 and 8, the rear lip 22 provides an opening for sliding the lower nub of a trailing decking plank. FIG. 8 depicts installation of a second decking plank by sliding under the rear lip 22 of the attached fastener. The bend 20 is positioned to trap the lower nub of the trailing decking plank with the support member 42. FIG. 9 shows the installed fastener holding the first and trailing decking planks via compressive downward force against the support member 42, without requiring additional tightening or penetration of the decking planks.

A decking structure is assembled by attaching third, fourth, etc. planks via the same process. Notably, the configuration of the prongs 16, which contact and/or slightly penetrate the lower nub during installation, and the legs 14 with forward extending prongs 16 assist substantially in maintaining the fastener generally level or parallel to the respective planks during attachment with the securing member. The prongs 16 may mate with or slightly penetrate the front surface of the lower plank nub during attachment, as shown most clearly in the enlarged depictions of FIGS. 7 and 9. This is especially advantageous when employed with plank grooves that are lower (i.e., having smaller lower nubs). Attachment of the fasteners with the elongated securing members 46 can be accomplished by employing a power driving tool, much as described in co-owned U.S. application Ser. Nos. 13/030,625, 13/169,175 and 13/532,145.

The collated series of fasteners, like the series 200 depicted in FIG. 3 (collated embodiments also shown in FIGS. 14-16), carries numerous advantages over known individual or loose fasteners. Packaging and handling a relatively rigid collated series is more facile and can be more efficient than numerous individual fasteners. The notched collation (see enlarged portion of FIG. 17, for example) allows and/or promotes severance of the adjacent fasteners. A user can optionally remove a fastener from the series by hand prior to installation. In other embodiments, driving a securing member through the attachment opening simultaneously disengages the subject lead fastener from the adjacent fastener in the series while installing the lead fastener on the plank.

In addition, collated series of fasteners like those depicted can be used within an automatic or semi-automatic track-like feeding system, similar to a magazine in a power driving tool like a nail gun (not depicted). A track-like rail attachment may be attached and positioned appropriately on a power driving tool or even formed within the power tool itself. The track is configured to engage with the collated fastener series such that, as the lead fastener is attached to the decking plank, the remaining fasteners advance down the track automatically, for example by a rear spring or other bias. After advancement of the series, the new lead fastener (the fastener which was adjacent and joined to the installed fastener) is positioned and held in position for an elongated securing member to be driven through its respective attachment opening. The configuration of the generally flat body 12 (and 112 discussed below), legs 14 (and 114, 115 discussed below), and outward bellow (shown as reference numerals 34 and 134) facilitate advancement, stopping, aligning and stabilization of the disclosed fastener or collated series of fasteners at a desired installation position within a rail feeing system of an automatic or manual installation tool. One of skill in the art would readily realize that alternative advancement mechanisms may be employed, such as for example a rotating wheel.

Notably, the variable nature of the penetration of the legs 14 into the joist, as well as the frontward extending prongs 16 allow the disclosed fastener to be used with a large variety of grooved decking planks—planks of different materials and groove styles or sizes.

FIG. 10 shows another embodiment of the disclosed universal fastener 110. The fastener 110 includes a body 112 spacing apart two legs, 114 and 115, which extend downwardly from shoulders 134 on opposite lateral edges of the base 112. Like the previous embodiments, the legs each include a plurality of frontward projecting prongs 116. As shown most clearly in FIGS. 11 and 12, the legs 114 and 115 are angled modestly toward the front end of the fastener 110. More specifically, the legs (114 and 115) have a front edge, shown generally as reference numeral 145 in FIG. 12, angled obliquely forward so that they lie at an angle less than perpendicular to the plane defined by the flat body portion. Preferred embodiments have legs that are angled at approximately 3°-15° from a line perpendicular to the plane defined by the body 112, and more preferably at approximately 5° relative thereto.

Like the previous embodiments, the body 112 has a generally flat portion which transitions to a lip 122 at the rear end for facilitating engagement of a trailing grooved decking plank after the fastener 110 has been used to attach a leading decking plank to a support member (i.e., joist). A typical installation may be performed substantially as shown in FIGS. 4-9 above. The lip has a tail 124 extending therefrom, similar to the tail 24 of the previous embodiments. Also like the previous embodiments, a nose 125 extends outwardly from the front end of the body 112. The front end also includes teeth 130 formed as bends in the opposite lead corners of the body 112. An alternate embodiment exists without the teeth, just as in the previously-disclosed embodiments.

Shown in FIGS. 11 and 13 is an outwardly projecting dimple 132 in the leg 115. The dimple 132 is formed in one leg (but not both) to provide an element of asymmetry to the fastener 110. The dimple 132 acts as an orientation guide, preventing backward loading of the fastener 110 (or series of fasteners, as will be discussed below) into an appropriately cooperating advancement track of a power driving tool for attachment. A cooperating track has a groove along one side configured to mate with the dimple 132 to guide installation and advancement of the fastener. Other embodiments of an asymmetric guide may be employed, such as for example a groove in one side of the fastener 110 (or one leg) which cooperates with a dimple or extension in the advancement track of the power driving tool. The described asymmetric element may be employed in any of the fastener embodiments of this disclosure.

FIG. 14 shows a collated series of fasteners 300 with the adjacent fasteners (110, 111, 113) connected via nose-to-tail attachment. FIG. 17 is an enlarged view of the connection between a fastener nose 125 and the tail 124 of the adjacent fastener, which has been discussed above.

As shown in FIG. 10, the body 112 defines an attachment opening 118 with a reverse (downward) radial dimple 126 formed as an extrusion through the body 112. With reference to FIG. 15, the downward extruded configuration of the attachment opening 118 allows the fasteners 110 to be pre-set with elongate securing members (screws, nails, etc.), like those shown as reference numeral 307. The reverse dimple 126 contour captures and reliably maintains the securing member 307, while also improving guidance of the securing member while it is driven through the opening 118. A collated series 300 of fasteners (110, 111, 113) with pre-set securing members 307 can be loaded into a loading magazine track as a single unit, thereby decreasing the number of separate parts and increasing reliability of installation. Installation can be achieved as described above with a power driving tool or simply by hand with a hammer or screwdriver. Similarly, a collated series of fasteners without pre-set securing members can be loaded into a driving tool as well. The configuration of the attachment opening 118 depicted in the Figures is non-limiting. Embodiments exist having variations of the depicted configuration, including as a half or partial extrusion through the body 112 for maintaining securing members.

Packaging and handling of the above-described pre-set fastener/securing member assemblies may cause disengagement of the securing members from the fasteners prior to use. It has been shown that an additional securement aid may be employed to provide additional adhesion between the respective securing members and fasteners. Such additional securement aids may include without limitation bushings, adhesives, grommets or eyelets.

With respect to all embodiments, the generally U or C-shaped fasteners having a substantially flat body between two opposite legs facilitates alignment and carrying of the fasteners (in a collated series or otherwise) on a rail advancement or delivery system (similar to a staple gun). The fastener legs can be bellowed slightly outward away from the central axis, as depicted by shoulders 34 and 134. The front edge of the legs 114 and 115, and shoulder 134 can cooperate with a positive stopper mechanism of an automatic feeding system (usually toward the front end) to aid in alignment before attachment via a driven securing member. Preferably, the positioning of the attachment opening and legs relative to the front and rear of the fastener body allows installation of the fastener with the securing member as close to tangent with the front edge of the decking plank. This position of the fastener has been shown to provide the optimal gapping between adjacent planks, as well as allows for relatively facile extraction of the fastener after the deck is complete as may be necessary for repair or disassembly.

The undercut portion, 43 and 143, in the rear edges of the respective legs, 14, 15, 114 and 115 (and/or the legs of the earlier embodiments), allows installation of the trailing decking plank at the rear end of the attached fastener into a closer abutment with the already-attached plank. Spacing between adjacent planks is minimized. This configuration and arrangement allows the adjacent decking planks to overlap and substantially cover or conceal the attached fasteners (10, 100, 110, 111, 113, etc.) from view.

Preferably, adjacent fasteners in a collated series (see FIGS. 3, 14-16) are rigidly connected via their respective adjacent noses and tails. The strong, rigid engagement allows application of a stronger frontward force (by a rear spring charge or otherwise) without a substantial risk of the series of fasteners buckling or the individual fasteners inadvertently detaching. The notches 136 (see FIG. 17) at the nose-tail interface facilitate severance of the front fastener from the adjacent fastener in the series by driving a securing member through the attachment opening. The entire series may be formed from a single sheet of rigid, strong formable material such as steel or another metal by a stamping or like process.

Another embodiment of the disclosed fastener 410 and a collated series 400 is depicted in FIGS. 19-21. This embodiment of the fastener 410 is similar to the earlier embodiments in many ways, including comprising a body 412 with a substantially flat portion, and which defines an attachment hole 418. A dimple or dome 426 may circumscribe the attachment hole 418 and project from the top surface of the body for assisting a tight engagement with an elongate securing member. The body 412 extends from a front end to a rear end between two opposite legs, 414 and 415. As shown most clearly in the side views of FIGS. 20 and 22, each leg 414 and 415 is angled obliquely forward relative to a hypothetical vertical line that is perpendicular to the flat or planar body 412. Like the previous embodiments, the rear and front edges include an undercut portion (443 and 447) leading to a lower portion 445 that may also be angled obliquely forward. Like earlier embodiments, the front end of the body 412 may also include a pair of prongs 430, each prong being formed as a bend in an opposite corner of the front edge. Also like the earlier embodiments, due to the respective undercut portions 443 and 447 in the front and rear edges of the legs, the lower portion of each leg has a front-to-rear thickness that is smaller than the upper portion of the leg (and shoulder).

FIGS. 19 and 20 depict a collated series 400 of the fasteners, which extend from a leading fastener 411 to intermediate fasteners 410 and a trailing fastener 413. As shown, the leading fastener 411 has a tail 424 for attachment to a nose 425 in the adjacent intermediate fastener 410. Each of the intermediate fasteners 410 includes a tail 424 and a nose 425, whereas the leading fastener 411 has only a tail 424 and the trailing fastener has only a nose 425.

The primary distinction between this embodiment of the fastener 410 and earlier embodiments is the presence of rear downwardly projecting teeth 422. Each of the rear teeth 422 is formed as a bend in each rear corner of the otherwise substantially flat body 412. In the preferred embodiment depicted in FIGS. 19-22, the rear teeth 422 have a rounded outer edge surface 449, rather than terminating at a point like the front teeth 430. This is not a limiting characteristic, as additional embodiments exist with rear teeth that terminate at a point, as well as embodiments with front teeth having rounded outer edge surfaces.

The embodiment of the fastener 410 is typically installed to form a decking structure just like the earlier embodiments disclosed above and depicted generally in FIGS. 4-9.

Notably, this embodiment of the fastener 410 offers a notable benefit in allowing a central portion of the bottom surface of the body 412 to remain substantially flat the entire front-to-rear length. That is, there is no bend across the entire lateral width of the body. This property allows improved housing and feeding of the fastener 410 or strip of fasteners 400 in an advancement tool with a track and central rail. A lower clearance height within the track is required since the fasteners 410 can lay flat with the entire length of the bottom surface against a central rail, thereby affording a constant height above the rail. A reduced clearance within the track carries added benefits, including reducing undesired overlapping and jamming of fasteners. Further, in an installation, the rear prongs 422 have been shown to provide additional resistance to thermal expansion.

While a preferred embodiment has been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit of the invention and scope of the claimed coverage. 

What is claimed is:
 1. A fastener for attaching a decking member to a support member, comprising a body extending from a front end to a rear end and including a top surface with a generally flat portion defining a plane extending between two opposing lateral edges, the body defining an attachment opening extending from a top surface to a bottom surface thereof, a downwardly projecting first leg extending from one lateral edge and an opposite downwardly projecting second leg extending the other lateral edge, each leg being defined between respective opposite front and rear edges, the front and rear edges of each leg extending from a portion of the respective lateral edge intermediate the front and rear end of the body, each leg having an undercut portion in its front edge and rear edge.
 2. The fastener of claim 1, comprising a dimple circumscribing the attachment opening, the dimple projecting upward from the top surface of the body.
 3. The fastener of claim 1, comprising teeth formed as downward bends from two opposing corners of the front end of the body.
 4. The fastener of claim 1, comprising teeth formed as downward bends from two opposing corners of the rear end of the body.
 5. The fastener of claim 1, wherein each leg extends downward at a forwardly oblique angle relative to a plane defined by the flat portion of the body.
 6. The fastener of claim 1, wherein each leg extends at an angle that is within a range of 3°-15° from perpendicular to the plane defined by the flat portion of the body.
 7. The fastener of claim 6, wherein each leg extends at an angle that is approximately 5° from perpendicular to the plane defined by the flat portion of the body.
 8. The fastener of claim 1, comprising front teeth formed as downward bends from two opposing corners of the front end of the body and rear teeth formed as downward bends from two opposing corners of the rear end of the body.
 9. The fastener of claim 8, comprising a laterally projecting shoulder extending from each lateral edge and transitioning downward to a respective leg.
 10. The fastener of claim 1, comprising a tail extending from a rear edge, the tail being joined to an additional fastener.
 11. The fastener of claim 1, wherein the front edge of each leg is angled obliquely forward from the plane defined by the body flat portion.
 12. The fastener of claim 1, wherein the attachment opening is positioned in the body substantially aligned with the legs in the front to rear direction.
 13. A fastener for attaching a decking member to a support member, comprising a body with a top surface and a bottom surface having a substantially planar portion and extending longitudinally between a front edge and a rear edge and laterally between two opposite lateral edges, the body defining an attachment opening from the top surface to the bottom surface, a first shoulder defined between a front edge and rear edge each positioned longitudinally intermediate the front edge and rear edge of the body, the first shoulder extending laterally from one lateral edge and transitioning downward to a downwardly projecting first leg and a second shoulder defined between a front edge and rear edge each positioned longitudinally intermediate the front edge and rear edge of the body, the second shoulder extending laterally from the opposite lateral edge at a longitudinal position intermediate the front and rear edges to a downwardly projecting second leg, each leg being angled obliquely forward relative to the planar portion of the bottom surface and having an undercut portion in its rear edge.
 14. The fastener of claim 13, wherein each of the legs has an undercut portion in its front edge.
 15. The fastener of claim 13, wherein the rear edge of each leg has an undercut portion at substantially the same position in the respective rear edge.
 16. The fastener of claim 13, wherein the body has the front edge with two corners, comprising a prong formed as a bend in each of the front corners.
 17. The fastener of claim 13, comprising a raised dimple circumscribing the attachment opening and projecting above the top surface of the body.
 18. The fastener of claim 13, wherein each leg extends at an angle that is within a range of 3°-15° from perpendicular to the plane defined by the flat portion of the body.
 19. The fastener of claim 18, wherein each leg extends at an angle that is approximately 5° from perpendicular to the plane defined by the flat portion of the body. 